Board cover and board covering system

ABSTRACT

A cover for a board is disclosed and comprises a sheet. The sheet has a pair of sides and a pair of ends. The sheet, in use, is disposed lengthwise upon said board. For and extending from each side of the sheet is provided a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet. The flanges, in use, extend in a common direction from the sheet, on opposite sides of said board.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority of U.S. Provisional Application Ser.No. 61/366,990 filed Jul. 23, 2010, which is incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to building products.

BACKGROUND TO THE INVENTION

The deleterious effects of moisture upon structures constructed fromwooden boards, such as decks, docks and walkways, are well known.Moisture can progressively deteriorate wood. There are other problemsassociated with the deterioration of wooden structures. Such structurescan be extremely costly, especially in a climate of increasing costs fornatural resources. In view of these factors, innovations to prevent wooddeterioration, such as pressure treating have become prevalent.

SUMMARY OF THE INVENTION

Forming one aspect of the invention is a cover for a board. The covercomprises: a sheet having a pair of sides and a pair of ends, the sheet,in use, being disposed lengthwise upon said board; and for and extendingfrom each side of the sheet, a flange, the flange being either fixed atabout 90 degrees to or pivotably attached to the sheet. The flanges, inuse, extend in a common direction from the sheet, on opposite sides ofsaid board.

According to another aspect of the invention, the flanges can each bemovable between an extended position, whereat the flanges extend fromthe sheet in substantially coplanar relation to the sheet, and a useposition, whereat the flanges extend in the common direction insubstantially perpendicular relation to the sheet.

According to another aspect of the invention, the flanges can be sizedand dimensioned such that, in use, the flanges substantially cover thesides of the board.

According to another aspect of the invention, the cover can furthercomprises at least one protrusion projecting from the sheet such that,in use, the protrusion and the flanges all extend in the commondirection.

According to another aspect of the invention, the cover can furthercomprise a plurality of protrusions projecting from the sheet such that,in use, the protrusions and the flanges all extend in the commondirection, the protrusions, in use, supporting the sheet above the boardfor foot traffic while permitting air flow beneath the sheet and boardas well as drainage.

According to another aspect of the invention, the flanges can be shapedsuch that, if a pair of covers are disposed in side by side relation onadjacent boards, with the adjacent flanges thereof abutting, voids aredefined between the abutting flanges to permit drainage.

According to another aspect of the invention, the sheet and flanges canbe injection-molded as a single unit.

According to another aspect of the invention, each side of the sheet canhave a single flange.

According to another aspect of the invention, the one end of the covercan be adapted to be mechanically secured to the board by screws.

According to another aspect of the invention, the sheet can besubstantially rectangular.

According to another aspect of the invention, the cover can have endsthat correspond with the ends of the sheet; one end of the cover can beadapted to be mechanically secured to said board in use; and the ends ofthe cover can be adapted such that, if a pair of the covers are disposedin use with one of the pair of covers secured to said board by the oneend thereof, and the other of the pair of covers is disposed adjacentthe one end of the one of the pair such that the sheets of the pair arein end to end close fitting relation, the abutting end of the other ofthe pair of covers is secured held against said board by the one end ofthe one of the pair of covers.

According to other aspects of the invention: the ends of the cover canbe provided with a locking arrangement such that, if a pair of thecovers are disposed in spaced end to end relation on a board and urgedtogether, the proximal ends engage one another in snap fit relation; andthe snap fit relation can provides for spaced, close-fitting relationbetween the adjacent sheets, the spaced relation allowing for the coversto expand lengthwise without buckling in normal hot weather conditions.

A system for covering a plurality of boards forms another aspect of theinvention. The system comprises covers and strip foam material. Eachcover includes: a substantially rectangular sheet having a pair of sidesand a pair of ends; and, for and extending from each side of the sheet,a flange, the flange being either fixed at about 90 degrees to orpivotably attached to the sheet. The covers are deployed in use suchthat, on each of said plurality of boards, a plurality of covers isdisposed with the sheets thereof in close fitting end-to-end relationand the flanges thereof extending from the sheets and between theboards. The foam material is wider than the board width and deployed inuse such that, on each of said plurality of boards, foam material isfitted between the boards and the covers so as to cover the surface ofthe board on which the sheets are positioned and to extend at leastpartially along each side of the board beneath the flanges.

Other advantages, features and characteristics of the present invention,as well as methods of operation and functions of the related elements ofthe structure, and the combination of parts and economies ofmanufacture, will become more apparent upon consideration of thefollowing detailed description and the appended claims with reference tothe accompanying drawings, the latter being briefly describedhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments of the present invention will now be described byreference to the following drawings, which illustrate by way of exampleonly preferred embodiments of the invention:

FIG. 1 is a top perspective view of the cover with the flanges in afirst extended position;

FIG. 2 is a top perspective view of the cover with the flanges in asecond use position;

FIG. 3 is a bottom perspective view of the cover with the flanges in afirst extended position;

FIG. 4 is a top plan view of the cover;

FIG. 5 is a bottom plan view of the cover;

FIG. 6 is a side plan view of the cover;

FIG. 7 is a front plan view of the cover;

FIG. 8 is a cross-sectional view along line A-A of FIG. 4;

FIG. 9 is a cross-sectional view of the cover along section B-B of FIG.4;

FIG. 10 is a top perspective view of a plurality of covers covering aplurality of boards;

FIG. 11 is a further top perspective view of a plurality of coverscovering a plurality of boards;

FIG. 12 is a top plan view of a plurality of covers covering a pluralityof boards;

FIG. 13 is a front plan view of a plurality of covers covering aplurality of boards; and

FIG. 14 is a side plan view of a plurality of covers covering aplurality of boards.

FIG. 15 is a top perspective view of a board cover according to anotherexemplary embodiment of the invention;

FIG. 16 is a bottom perspective view of the cover of FIG. 15;

FIG. 17 is a top plan view of the board cover of FIG. 15;

FIG. 18 is a bottom plan view of the board cover of FIG. 15;

FIG. 19 is a side view of the board cover of FIG. 15;

FIG. 20 is a view along 20-20 of FIG. 17;

FIG. 21 is an end view of the board cover of FIG. 15;

FIG. 22 is a view along 22-22 of FIG. 17;

FIG. 23 is a perspective view of the structure of FIG. 15, configuredfor use;

FIG. 24 is a top plan view of a plurality of the covers of FIG. 23, inuse;

FIG. 25 is a side view of the structure of FIG. 24; and

FIG. 26 is an end view of the structures of FIG. 24.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present invention will now described for the purposes ofillustration only in connection with certain embodiments. However, it isto be understood that other objects and advantages of the presentinvention will be made apparent by the following description of thedrawings according to the present invention. While an exemplaryembodiment is disclosed, this is not intended to be limiting. Rather,the general principles set forth herein are considered to be merelyillustrative of the scope of the present invention and it is to befurther understood that numerous changes may be made without strayingfrom the scope of the present invention.

Referring to FIG. 1, there is shown in perspective view an exemplaryembodiment of a cover 100 according to the present invention.

The cover 100 is manufactured from a rigid yet pliable material. Thematerial comprising the cover 100 is also preferably water-resistant orwaterproof. Examples of the material from which the cover 100 ismanufactured include plastic, non corrosive sheet metal, and rubber. Thecover 100 may also be manufactured from a combination of materials, forexample by co-molding rubber over plastic, or rubber over formed sheetmetal.

The cover 100 has a sheet 110. FIG. 1 depicts the sheet 110 as having arectangular shape so as to correspond with a board (not shown) havingsubstantially straight edges. Those having ordinary skill in the artwill appreciate that the sheet 110 could be shaped in any manner tocorrespond with the shape of a board beneath the sheet 110.

The width of the sheet 110 is at least the width of the board beingcovered. Thus, for structures constructed from four inch wide boards,the sheet 110 is at least four inches wide. For structures constructedfrom five and one half inch wide boards, the sheet 110 is at least fiveand one half inches wide.

As may be better appreciated from a consideration of FIG. 13, the widthof the sheet 110 may be slightly greater than the width of a top surfacea board 120 covered by the cover 100.

In this exemplary embodiment of the cover 100, the sheet 110 includes ameans for creating friction on an outer surface 144 of the sheet 110.The means for creating friction shown in FIG. 1 is a series ofprotuberances 150 formed in the outer surface 144 of the sheet 110. Itwill be recognized by a person skilled in the art that other means forcreating friction could be utilized, such as a series of alternatinggrooves and ridges.

The protuberances 150 are equally distributed upon the outer surface 144of the sheet 110 in a grid pattern. Further, as may be betterappreciated from consideration of FIGS. 6 and 7, the protuberances 150are bevelled.

FIG. 3 shows an inner surface 156 of the sheet 110. The inner surface156 of the sheet 110 includes at least one protrusion for engaging thetop surface 124 of the board 120. It will be appreciated by one skilledin the art that the purposes of the invention may be achieved if oneemploys any number of protrusions shaped and arrayed so as to separatethe inner surface 156 of the sheet 110 and the top surface 124 of theboard 120. As shown in FIG. 3, the protrusions are a plurality of ribs160. These ribs 160 are orientated parallel to one another and in twoseries 164 and 168 that define a channel 170.

Near a first end 180 of the cover 100, four short ribs 162 areorientated across the width of the sheet 110 and parallel to the ribs160. The ribs 160 and the short ribs 162 are formed in the inner surface156 of the sheet 110.

The first end 180 of the sheet 110 and a second end 190 of the sheet 110are adapted to include attachment means. It will be appreciated by aperson skilled in the art that the purposes of the invention may beachieved by employing any attachment means including hooks, clasps, orthe like. In the embodiment described herein, the attachment meansconsist of two outer female tabs 200 and two inner female tabs 206situated at the first end 180 of the sheet 110 and two outer male tabs210 and an inner male tab 216 situated at the second end 190 of thesheet 110. The female tabs 200 and 206 and the male tabs 210 and 216 areformed in the inner surface 156 of the sheet 110.

The distance between the inner female tabs 206 is equal to the distancebetween each inner female tab 206 and an adjacent outer female tab 200.The outer female tabs 200 are slightly wider than the inner female tabs206. Each of the female tabs 200 and 206 correspond with a short rib 162such that the distances between adjacent female tabs 200 and 206 matchcorresponding distances between short ribs 162.

The distance between the inner male tab 216 and each outer male tab 210is at least equal to the width of inner female tabs 206. The distancebetween each outer male tab 210 and the closest of the first edge 130 ofthe sheet 110 and the opposing edge 136 of the sheet 110 is at leastequal to the width of the outer female tabs 200.

Each male tab 210 and 216 defines an aperture 220 sized so as to receivea fastener (not shown) such as a screw, a nail or the like.

The cover 110 includes a plurality of flanges. In the preferredembodiment depicted herein, the cover 110 has two flanges. It will beappreciated by a person skilled in the art that the purposes of theinvention can be achieved by incorporating two or more flanges.

A first flange 300 is attached adjacent to the first edge 130 of thesheet 110 and a second flange 310 is attached to the sheet 110 adjacentto the second edge 136 of the sheet 110. The length of the flanges 300and 310 is equal to the length of the sheet 110. The height of theflanges 300 and 310 is preferably equal to or greater than the height ofsides 124 and 126 of board 120.

The flanges 300 and 310 are either fixed at about 90 degrees as in FIG.2 (for sheet metal and plastic made parts without fold line-live hinge)or pivotably attachable to the sheet 110 (for plastic parts with foldline-live hinge). It will be appreciated by a person skilled in the artthat the purposes of the invention may be achieved employing anyconventional means for pivotably attaching the flanges 300 and 310 tothe sheet 110. A top edge of each flange is bevelled as demonstrated bytop edge 304 of flange 300 shown in FIG. 7.

As may be appreciated by considering FIGS. 7 and 9, the flanges 300 and310 are each attached to the sheet 110 by a hinge 320. In thisembodiment, the hinge 320 extends along the entire length of the sheet110 so as to create an integral attachment.

The first edges 324 of each hinge 320 are bevelled so as to permit thehinge 320 to pivot downward from a first extended position wherein thehinge flares away from the sheet 110 to a second use position where,upon rotation of the hinge 320 about a point where the hinge 320attaches to the sheet 110, the hinge 320 is orientated more proximate tothe sheet 110. Similarly, a second edge 328 of each hinge 320 isbevelled so as to permit, for example, the first flange 300 to rotateabout a point at which the hinge 320 attaches to the first flange 300from a first position wherein the first flange 300 is parallel to theplane of the sheet 110 to a second position wherein the first flange 300is perpendicular to the plane of the sheet 110.

Each flange may have a series of bosses 330 on an outer surface 304 ofthe flange. Each boss 330 is integrally formed in the flange. The bosses330 can be equally spaced along the length of each flange. Further, asseen in FIG. 1, the bosses 330 may be equally sized. If necessary,narrow bosses 334 at ends of the flanges may be smaller sized thanbosses 330 so as to preserve the uniform spacing between the bosses.

FIGS. 11 to 14 depict the cover 100 in operation with other covers 100.Multiple covers 100 may be attached to create a system for covering theboard 120. Alternatively or additionally, one or more covers 100 may bepositioned upon adjacent boards 120 to create a system for coveringmultiple boards.

Before affixing the cover 100 upon the board 120 the flanges 300 and 310are pivoted about hinges 320 from the first position to the secondposition so that the flanges 300 and 310 are orientated perpendicular tothe plane of the sheet 110 and the hinges 320 are orientated so as topermit the cover 100 to fit snugly upon the board 120. The cover 100 isthen placed upon the board 120. The cover 100 can be placed upon theboard 120 in a snug fit as best depicted in FIG. 13 such that eachflange engages a side 126 or 128 of the board 120 and the ribs 160engage the top surface 124 of the board 120. Accordingly, the cover 100is centered upon the board 120.

The cover 100 is then fastened to the board 120. Fasteners (not shown)are placed within apertures 220 of male tabs 210 and 216 and attached tothe board 120.

A second cover 104 is then attached to the first cover 100. The flangesof the second cover 104 are pivoted to the second position wherein theflanges are perpendicular to the plane of the sheet of the second cover104. The second cover 104 is then slidably placed upon the board 120such that the female tabs 200 and 206 of the cover 100 receive the maletabs of the second cover 104.

As seen in FIGS. 12 and 14, preferably, a second end 184 of the secondcover 104 is placed slightly distal from the first end 180 of the sheet110 of the cover 100 so as to define a space 340 between a second end184 of the second cover 104 and the first end 180 of the sheet 110 ofthe cover 100 and a first end 180 of the second cover 104. The width ofthe space 340 may be 0.1 inches to permit thermal expansion of the cover100 and the second cover 104 without causing damage to the covers ordeterioration of the board 120.

Similarly, further covers may be affixed to the board 120 to cover adesired length of the board 120.

As best shown in FIG. 13, adjacent cover 108 may be affixed to anadjacent board 122 to create a system for covering multiple boards. Theflanges 314 and 318 of the adjacent cover 108 are pivoted to the secondposition so that the flanges 314 and 318 of the adjacent cover 108 areperpendicular to the sheet 114 of the adjacent cover 108. The adjacentcover 108 is then slidably placed upon the adjacent board 122 andpositioned such that adjacent bosses 336 of the flange 314 of theadjacent cover 108 are adjacent to the corresponding bosses 330 of theflange 310 of cover 100, as depicted in FIG. 12. The adjacent cover 108is then fastened to the adjacent board 122 in a manner similar to thatdescribed above in respect of the fastening of the cover 100 to theboard 120. The flange 314 of the adjacent cover 108 and the flange 310of the cover 100 define a gap 350. One or more additional covers may beplaced upon adjacent board 120 and fastened. One or more additionalcovers may be affixed to further adjacent boards.

Persons of ordinary skill will appreciate that the foregoing arrangementhas substantial advantage:

the covers can be injection molded as a single piece

the pivotable nature of the flanges allow the covers to be densely flatpacked

the bosses ensure that, in use, drainage passages remain between thecovers

the upper protuberances provide stable footing to foot traffic, evenwhen wet

the ribs ensure airflow between the cover and board, to resist rot

FIGS. 15-26 show a cover according to another exemplary embodiment ofthe invention, which cover is designated with general reference numeral400. This cover 400 has functionality substantially similar to thecovers previously disclosed. For simplicity, to the extent that thiscover 400 is similar to the previously-described covers, a detaileddescription is neither required nor provided: reference is simply madeat this time to the reference numerals on FIGS. 15-26 which correspondto those found in the previous description, and it is hereby confirmedthat structures on FIGS. 15-26 which share reference numerals withstructures on FIGS. 1-14 operate in an identical or substantiallysimilar fashion. The structure of FIGS. 15-26 does differ somewhat fromthe structure of FIGS. 1-14, and these differences are describedhereinbelow.

Locking Arrangement

As best seen in FIGS. 15-16, this cover 400 includes a lockingarrangement, which is defined by, on one end of the cover [the end whichincludes outer male tabs 210], a pair of resilient locking fingers 502provided with notches 504 and, on the other end of the cover, a pair oflocking detents 506. The fingers 502 are arranged to slide along thefemale tabs 206, ride up over the detents 506 and then snap back intotheir original positions once the detents 506 can occupy the notches504. This snap-fit engagement spaces the longitudinally-adjacent sheetsslightly apart from one another to permit thermal expansion withoutbuckling, as discussed earlier.

Pilot Holes

As best seen in FIGS. 15 and 20, the cover 400 includes a plurality ofpilot holes 508 on the upper surface which align with stud protuberances510 that extend from the lower surface of the cover. The studprotuberances 510 function in a manner analogous to ribs 164, but have agirth that is sufficient to allow a finishing nail to pass therethrough.This arrangement allows, inter alia, the cover to be cut to length andsecured in place.

Flange Insets

As illustrated in FIG. 15, this cover 400 has flange insets 512 whichare shaped and dimensioned such that, when another cover is disposedupon the same board in longitudinally end to end close fitting relation,the flanges of the adjacent cover are received in and overlap the flangeinsets 512.

System

The cover of this embodiment can be used in a manner similar to thatshown in FIG. 10, as evidenced by FIGS. 24-26. However, as a yet furtherembodiment, this cover, as well as the cover of FIGS. 1-14, can be usedas part of a system which includes strip foam material strip foammaterial, the foam material being wider than the board width anddeployed in use such that, on each of said plurality of boards, foammaterial is fitted between the boards and the covers so as to cover thesurface of the board on which the sheets are positioned and to extend atleast partially along each side of the board beneath the flanges. Thissystem provides even better protection for the boards from the elements,in that the entire upper surface of the board is shielded fromprecipitation. This system also has advantage, in that it provides acushion for the covers, which reduces noise production in use.

Variants

In a yet further alternative embodiment, not shown, the strip foammaterial can be omitted, and the stud protuberances and ribs can befaced on their lower surface with foam material. This increases cost butincreases airflow beneath the covers. This also allows waterinfiltration at the junction of the longitudinally adjacent covers, butthis can be ameliorated, for example, by foam tape at the joints.

In a yet further alternative embodiment, not shown, the ribs can beremoved and the stud protuberances can be pointed, lengthened and mademore plentiful. The reduced contact area, coupled with the potential forslight penetration of the protuberances into the wood surface, willreduce noise production, but will slightly damage the wood, which maynot be desirable in all situations.

As yet further options, the cover can itself be covered with carpeting.In one embodiment, polypropylene outdoor carpet is fused via anovermolding process to the cover, such that the covers function as‘carpet tiles’. In another embodiment, outdoor carpet can be secured, byself-adhesive backing on the carpet, after the covers have themselvesbeen installed.

It will be apparent to those having ordinary skill in the art thatvarious modifications and variations may be made to the embodimentsdisclosed herein, consistent with the present invention, withoutdeparting from the spirit and scope of the present invention.Accordingly, the specification is to be considered exemplary only, withthe true scope and spirit of the invention being disclosed by thefollowing claims, purposively construed.

1. A cover for a board, the cover comprising: a sheet having a pair ofsides and a pair of ends, the sheet, in use, being disposed lengthwiseupon said board; and for and extending from each side of the sheet, aflange, the flange being either fixed at about 90 degrees to orpivotably attached to the sheet, the flanges, in use, extending in acommon direction from the sheet, on opposite sides of said board.
 2. Thecover of claim 1, wherein the flanges are each movable between anextended position, whereat the flanges extend from the sheet insubstantially coplanar relation to the sheet, and a use position,whereat the flanges extend in the common direction in substantiallyperpendicular relation to the sheet.
 3. The cover of claim 1, whereinthe flanges are sized and dimensioned such that, in use, the flangessubstantially cover the sides of the board.
 4. The cover of claim 1,further comprising at least one protrusion projecting from the sheetsuch that, in use, the protrusion and the flanges all extend in thecommon direction.
 5. The cover of claim 1, further comprising aplurality of protrusions projecting from the sheet such that, in use,the protrusion and the flanges all extend in the common direction, theprotrusions, in use, supporting the sheet above the board for foottraffic while permitting air flow beneath the sheet and board anddrainage.
 6. The cover of claim 1, wherein the flanges are shaped suchthat, if a pair of covers are disposed in side by side relation onadjacent boards, with the adjacent flanges thereof abutting, voids aredefined between the abutting flanges to permit drainage.
 7. The cover ofclaim 1, wherein the sheet and flanges are injection-molded as a singleunit.
 8. The cover of claim 1, wherein each side of the sheet has asingle flange.
 9. The cover of claim 1, wherein: the cover has ends thatcorrespond with the ends of the sheet; one end of the cover is adaptedto be mechanically secured to said board in use; and the ends of thecover are adapted such that, if a pair of the covers are disposed in usewith one of the pair of covers secured to said board by the one endthereof, and the other of the pair of covers is disposed adjacent theone end of the one of the pair such that the sheets of the pair are inend to end close fitting relation, the abutting end of the other of thepair of covers is secured held against said board by the one end of theone of the pair of covers.
 10. The cover of claim 9, wherein the one endof the cover is adapted to be mechanically secured to the board byscrews.
 11. The cover of claim 1, wherein the ends of the cover areprovided with a locking arrangement such that, if a pair of the coversare disposed in spaced end to end relation on a board and urgedtogether, the proximal ends engage one another in snap fit relation. 12.The cover of claim 11, wherein the snap fit relation provides forspaced, close-fitting relation between the adjacent sheets, the spacedrelation allowing for the covers to expand lengthwise without bucklingin normal hot weather conditions.
 13. The cover of claim 1, wherein thesheet is substantially rectangular.
 14. A system for covering aplurality of boards, the system comprising: covers, each coverincluding: a substantially rectangular sheet having a pair of sides anda pair of ends; and, for and extending from each side of the sheet, aflange, the flange being either fixed at about 90 degrees to orpivotably attached to the sheet, the covers being deployed in use suchthat, on each of said plurality of boards, a plurality of covers isdisposed with the sheets thereof in close fitting end-to-end relationand the flanges thereof extending from the sheets and between theboards; and strip foam material, the foam material being wider than theboard width and deployed in use such that, on each of said plurality ofboards, foam material is fitted between the boards and the covers so asto cover the surface of the board on which the sheets are positioned andto extend at least partially along each side of the board beneath theflanges.